To perform a similar ring-gear forging simulation using rezoning, consider the following hints and recommendations:
Use rezoning only in problems experiencing mesh distortion as a result of large deformation.
Select the substep to initiate rezoning carefully.
Determine the optimal substep after carefully examining the element solution, the deformed mesh, and the convergence pattern.
The best substep to rezone is the one where the mesh is distorted (though not too severely distorted) and the time increment is not close to (or at) its minimum.
Use an earlier substep or a better mesh if necessary.
If any of the following situations are encountered, initiate rezoning at an earlier substep or improve the quality of the new mesh:
-- Remeshing errors -- Error, failure, or convergence difficulty during remapping -- Convergence failure in the restarted analysis -- New mesh shape characteristics are bad due to distortion. More than one region can be remeshed at the same time.
Mesh size affects mapping.
If the new mesh size is drastically different from that of the old mesh, convergence issues may occur during mapping. It may be necessary to resize the new mesh to more closely match the old one.
Specify more substeps if needed.
A larger maximum number of substeps may need to be specified to handle convergence difficulties during mapping and in the restarted analysis.